Zoned Spinneret and High Loft Nonwoven Fabrics

ABSTRACT

A spinneret for melt-spinning polymeric fibers including a spinneret body including a plurality of spinning orifices formed through a thickness of spinneret body is provided. The plurality of spinning orifices include (i) a plurality of multicomponent spinning orifices comprising a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinning orifices comprising a single monocomponent opening. Nonwoven fabrics having regions of monocomponent and multicomponent fibers are provided as well as methods of forming such nonwoven fabrics utilizing a zoned-spinneret.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119 to U.S. Patent Application No. 63/357,196 filed Jun. 30, 2022, which is expressly incorporated by reference herein in its entirety.

TECHNICAL FIELD

Embodiments of the presently-disclosed invention relate generally a spinneret and a die including a spinneret, in which the spinneret includes zones configured to simultaneously melt-spin defined regions of monocomponent fibers and multicomponent fibers. Embodiments of the presently-disclosed invention also relate generally to nonwoven fabrics and methods of forming such nonwoven fabrics.

BACKGROUND

In nonwoven fabrics, the fibers forming the nonwoven fabric are generally oriented in the x-y plane of the web. As such, the resulting nonwoven fabric is relatively thin and lacking in loft or significant thickness in the z-direction. Loft or thickness in a nonwoven fabric suitable for use in hygiene-related articles (e.g., personal care absorbent articles) promotes comfort (softness) to the user, surge management, and fluid distribution to adjacent components of the article. In this regard, high loft, low density nonwoven fabrics are used for a variety of end-use applications, such as in hygiene-related products (e.g., sanitary pads and napkins, disposable diapers, incontinent-care pads, etc.). High loft and low density nonwoven fabrics, for instance, may be used in products such as towels, industrial wipers, incontinence products, infant care products (e.g., diapers), absorbent feminine care products, and professional health care articles

In order to impart loft or thickness to a nonwoven fabric, it is generally desirable that at least a portion of the fibers comprising the web be oriented in the z-direction. Conventionally, such lofty nonwoven webs are produced using crimped staple fibers or post-forming processes such as creping or pleating of the formed fabric. Although methods exist for producing high loft and low density fabrics, the fabrics are typically subjected to a number of processes during conversion which compress and/or deform the material. Compression of the fabric may reduce the overall bulk that was created while conveyance of the fabric in a machine direction during a variety of converting processes my induce undesirable elongation in the machine direction and/or necking (e.g., reduction in width in the cross-direction) that negatively impact the ability of the converting process due to the overall deformation of the fabric.

Therefore, there remains a need in the art for lofty nonwoven fabrics having improved resistance to deformation, such as elongation in a machine direction and/or width reduction in a cross-direction due to an external load or tension applied along the machine direction on the nonwoven fabric, and/or resistance to the formation of lint via abrasion. There also remains a need in the art for equipment and methods for making such lofty nonwoven fabrics

SUMMARY OF INVENTION

One or more embodiments of the invention may address one or more of the aforementioned problems. Certain embodiments according to the invention provide a spinneret for melt-spinning polymeric fibers including a spinneret body including a plurality of spinning orifices formed through a thickness of spinneret body, in which the plurality of spinning orifices include (i) a plurality of multicomponent spinning orifices comprising a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinning orifices comprising a single monocomponent opening; wherein the plurality of monocomponent spinning orifices may optionally include a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices.

In another aspect, the present invention also provides a die including (i) a spinneret as described and disclosed herein, (ii) a first polymer distribution pathway operatively connecting a first inlet to each of the first multicomponent openings of the plurality of multicomponent spinning orifices of the spinneret, (iii) a second polymer distribution pathway operatively connecting a second inlet to each of the second multicomponent openings of the plurality of multicomponent spinning orifices of the spinneret, (iv) a third polymer distribution pathway operatively connecting a third inlet to at least a first portion of the monocomponent openings of the plurality of monocomponent spinning orifices of the spinneret, such as the plurality of PCA monocomponent spinning orifices; and (v) optionally a fourth polymer distribution pathway operatively connecting a fourth inlet to at least a second portion of the single monocomponent openings of the plurality of monocomponent spinning orifices of the spinneret, such as the plurality of PCB monocomponent spinning orifices.

In another aspect, the present invention also provides a system including (i) a die as described and disclosed herein; (ii) a first polymer source comprising a first polymeric composition, wherein the first polymer source is operatively connected to a first inlet of the die, (iii) a second polymer source comprising a second polymeric composition that is different than the first polymeric composition, wherein the second polymer source is operatively connected to a second inlet of the die, and optionally (iv) a third polymer source comprising a third polymeric composition that is different than the first polymeric composition and the second polymeric composition, wherein the third polymer source is operatively connected to a third inlet of the die.

In another aspect, the present invention also provides a nonwoven fabric including a plurality of interlaid fibers comprising a plurality of monocomponent fibers, such as optionally a plurality of different types of monocomponent fibers including a plurality of first type of monocomponent fibers and a plurality of second type of monocomonent fibers, and a plurality of crimped multicomponent fibers, in which the nonwoven fabric includes at least one first region including at least a majority (e.g., all) of a first monocomponent-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority (e.g., all) of a first multicomponent-fiber group of the plurality of crimped multicomponent fibers.

In yet another aspect, the present invention also provides a method of producing a nonwoven fabric, such as those described and disclosed herein. The method, in accordance with certain embodiments of the invention, may include the following: (i) simultaneously melt spinning a set of fibers from a single spinneret, such as those described and disclosed herein, in which the set of fibers comprise a plurality of monocomponent fibers, such as optionally a plurality of different types of monocomponent fibers including a plurality of first type of monocomponent fibers and a plurality of second type of monocomonent fibers, and a plurality of multicomponent, and wherein the set of fibers form at least one first region including at least a majority of a first monocomponent-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority of a first multicomponent-fiber group of the plurality of multicomponent fibers; (ii) collecting the melt-spun set of fibers; and (iii) forming a plurality of crimped multicomponent fibers by actively and/or passively forming one or more crimped portions in at least a portion of the plurality of multicomponent fibers.

BRIEF DESCRIPTION OF THE DRAWING(S)

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout, and wherein:

FIG. 1A illustrates a spinneret including a zone of multicomponent spinning orifices and a zone of monocomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 1B illustrates a spinneret including a zone of multicomponent spinning orifices and a zone of monocomponent spinning orifices that includes a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 1C illustrates another spinneret including a zone of multicomponent spinning orifices and a zone of monocomponent spinning orifices that includes a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 2A illustrates a spinneret including a zone of monocomponent spinning orifices located adjacent and in between two zones of multicomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 2B illustrates a spinneret including a zone of monocomponent spinning orifices including a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices located adjacent and in between two zones of multicomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 3A illustrates a spinneret including a large zone of multicomponent spinning orifices located adjacent and in between a two smaller zones of monocomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 3B illustrates a spinneret including a large zone of multicomponent spinning orifices located adjacent and in between a two smaller zones of monocomponent spinning orifices in which one of the smaller zones of monocomponent spinning orifices comprises a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and the other smaller zone of monocomponent spinning orifices comprises a plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices in accordance with certain embodiments of the invention;

FIG. 4 illustrates a spinneret including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine direction (MD) when in operation in accordance with certain embodiments of the invention;

FIG. 5 illustrates a spinneret including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine-direction (MD) when in operation and a length direction (L) of the spinneret that may be associated with a cross-direction (CD) when in operation in accordance with certain embodiments of the invention;

FIG. 6 illustrates another spinneret including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine-direction (MD) when in operation and a length direction (L) of the spinneret that may be associated with a cross-direction (CD) when in operation in accordance with certain embodiments of the invention;

FIG. 7 illustrates another spinneret including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine-direction (MD) when in operation and a length direction (L) of the spinneret that may be associated with a cross-direction (CD) when in operation in accordance with certain embodiments of the invention;

FIG. 8 illustrates a spinneret including a plurality of separate zones of monocomponent spinning orifices dispersed throughout a single zone or sea of multicomponent spinning orifices;

FIG. 9A-9H illustrate examples of cross-sectional views for some example multi-component fibers in accordance with certain embodiments of the invention.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.

The presently-disclosed invention relates generally to spinnerets having a plurality of “zones” that may be defined, for example, spinning orifices have different shapes, sizes, and/or configurations (e.g., monocomponent spinning orifices configured to melt-spin monocomponent fibers, multicomponent spinning orifices configured to melt-spin one or more types of multicomponent fibers, etc.). For example, a grouping of a plurality of monocomponent spinning orifices may define a first zone while a plurality of multicomponent spinning orifices may define a second zone. In this regard, the spinneret may comprise a generally unlimited number of different zones (e.g., from a single spinning beam) that may be located respect to each other to enable melt-spinning of fibers for the production of nonwoven fabrics having a particularly desired structure that may be defined by respective location of corresponding groups of melt-spun fibers present within the nonwoven fabric (e.g., a single layer nonwoven fabric formed from a single spinning beam comprising a spinneret in accordance with certain embodiments of the invention. In accordance with certain embodiments of the invention, the spinneret may be incorporated into a melt-spinning die and/or a melt-spinning system that can distribute and spin multiple polymer compositions (e.g., 2, 3, 4, 5, 6 . . . different polymer compositions). By way of example, three separate polymer compositions may be simultaneously melt-spun in which a first polymer composition may form a first component of a multicomponent fiber, a second polymer composition may form a second component of the multicomponent fiber, and a third polymer composition may form monocomponent fibers. In accordance with certain embodiments of the invention, however, a particular polymer composition may be distributed within the same die to form both the monocomponent fibers and one of the components of the multicomponent fibers (e.g., bicomponent fibers).

In accordance with certain embodiments of the invention, nonwoven fabrics (e.g., lofty nonwoven fabrics formed with a spinneret as described and disclosed herein) incorporating the mixture of both monocomponent fiber and multicomponent fibers (e.g., crimped multicomponent fibers) in accordance with certain embodiments of the invention may provide a beneficial reduction in machine-direction (MD) and/or cross-direction (CD) as compared to similarly or identically loft nonwoven fabrics. Additionally or alternatively, nonwoven fabrics (e.g., lofty nonwoven fabrics formed with a spinneret as described and disclosed herein) incorporating the mixture of both monocomponent fiber and multicomponent fibers (e.g., crimped multicomponent fibers) in accordance with certain embodiments of the invention may provide reduction of “fuzz” or lint during abrasion as compared to similarly or identically loft nonwoven fabrics.

In accordance with certain embodiments of the invention, the total number or weight percent of the monocomponent fibers present in the nonwoven fabric may be selected to account for, by way of example only, less than about than say 40% (e.g., less than 33%, less than 30%, less than 25%, less than 20%, less than 15%, or less than about 10%). The lower amounts of monocomponent fibers, in accordance with certain embodiments of the invention, may provide the benefits of reduced elongation and/or improved resistance to lint formation due to abrasion while simultaneously maintaining a desired loft/thickess by not removing too many crimped multicomponent fibers. In accordance with certain embodiments of the invention, the selection of the location of the monocomponent fibers (e.g., via the selection of the location of the monocomponent spinning orifices in the spinneret) may be important when providing improved resistance to lint or “fuzz” formation during abrasion. For example, a smaller amount of monocomponent fibers near the outermost surface that touches the engraved roll (e.g., consolidation) may provide a “blanket” or “buffer” region of non-crimped fibers that may be less likely to become pulled out of plane during abrasion. Utilizing a smaller layer of these monocomponent fibers, however, that nonwoven fabric may retain loft/thickness via the underlying crimped multicomponent fibers. In accordance with certain embodiments of the invention, the level or degree of crimping of the underlying multicomponent fibers may improve loft. For instance, the degree of crimp formation may be increased since that small amount of monocomponent fibers provide a “blanket” or “buffer” region.

The terms “substantial” or “substantially” may encompass the whole amount as specified, according to certain embodiments of the invention, or largely but not the whole amount specified (e.g., 95%, 96%, 97%, 98%, or 99% of the whole amount specified) according to other embodiments of the invention.

The terms “polymer” or “polymeric”, as used interchangeably herein, may comprise homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” or “polymeric” shall include all possible structural isomers; stereoisomers including, without limitation, geometric isomers, optical isomers or enantionmers; and/or any chiral molecular configuration of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The term “polymer” or “polymeric” shall also include polymers made from various catalyst systems including, without limitation, the Ziegler-Natta catalyst system and the metallocene/single-site catalyst system. The term “polymer” or “polymeric” shall also include, in according to certain embodiments of the invention, polymers produced by fermentation process or biosourced.

The terms “nonwoven” and “nonwoven web”, as used herein, may comprise a web having a structure of individual fibers, filaments, and/or threads that are interlaid but not in an identifiable repeating manner as in a knitted or woven fabric. Nonwoven fabrics or webs, according to certain embodiments of the invention, may be formed by any process conventionally known in the art such as, for example, meltblowing processes, spunbonding processes, needle-punching, hydroentangling, air-laid, and bonded carded web processes. A “nonwoven web”, as used herein, may comprise a plurality of individual fibers that have not been subjected to a consolidating process. In certain instances, the “nonwoven web” may comprises a plurality of layers, such as one or more spunbond layers and/or one or more meltblown layers. For instance, a “nonwoven web” may comprises a spunbond-meltblown-spunbond structure.

The terms “fabric” and “nonwoven fabric”, as used herein, may comprise a web of fibers in which a plurality of the fibers are mechanically entangled or interconnected, fused together, and/or chemically bonded together. For example, a nonwoven web of individually laid fibers may be subjected to a bonding or consolidation process to bond at least a portion of the individually fibers together to form a coherent (e.g., united) web of interconnected fibers.

The term “consolidated” and “consolidation”, as used herein, may comprise the bringing together of at least a portion of the fibers of a nonwoven web into closer proximity or attachment there-between (e.g., thermally fused together, chemically bonded together, and/or mechanically entangled together) to form a bonding site, or bonding sites, which function to increase the resistance to external forces (e.g., abrasion and tensile forces), as compared to the unconsolidated web. The bonding site or bonding sites, for example, may comprise a discrete or localized region of the web material that has been softened or melted and optionally subsequently or simultaneously compressed to form a discrete or localized deformation in the web material. Furthermore, the term “consolidated” may comprise an entire nonwoven web that has been processed such that at least a portion of the fibers are brought into closer proximity or attachment there-between (e.g., thermally fused together, chemically bonded together, and/or mechanically entangled together), such as by thermal bonding or mechanical entanglement (e.g., hydroentanglement) as merely a few examples. Such a web may be considered a “consolidated nonwoven”, “nonwoven fabric” or simply as a “fabric” according to certain embodiments of the invention.

The term “spunbond”, as used herein, may comprise fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced. According to an embodiment of the invention, spunbond fibers are generally not tacky when they are deposited onto a collecting surface and may be generally continuous as disclosed and described herein. It is noted that the spunbond used in certain composites of the invention may include a nonwoven described in the literature as SPINLACE®. Spunbond fibers, for example, comprise continuous fibers.

As used herein, the term “continuous fibers” refers to fibers which are not cut from their original length prior to being formed into a nonwoven web or nonwoven fabric. Continuous fibers may have average lengths ranging from greater than about 15 centimeters to more than one meter, and up to the length of the web or fabric being formed. For example, a continuous fiber, as used herein, may comprise a fiber in which the length of the fiber is at least 1,000 times larger than the average diameter of the fiber, such as the length of the fiber being at least about 5,000, 50,000, or 100,000 times larger than the average diameter of the fiber.

The term “layer”, as used herein, may comprise a generally recognizable combination of similar material types and/or functions existing in the X-Y plane.

The term “multi-component fibers”, as used herein, may comprise fibers formed from at least two different polymeric materials or compositions (e.g., two or more) extruded from separate extruders but spun together to form one fiber. The term “bi-component fibers”, as used herein, may comprise fibers formed from two different polymeric materials or compositions extruded from separate extruders but spun together to form one fiber. The polymeric materials or polymers are arranged in a substantially constant position in distinct zones across the cross-section of the multi-component fibers and extend continuously along the length of the multi-component fibers. The configuration of such a multi-component fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another, an eccentric sheath/core arrangement, a side-by-side arrangement, a pie arrangement, or an “islands-in-the-sea” arrangement, each as is known in the art of multicomponent, including bicomponent, fibers.

The term “machine direction” or “MD”, as used herein, comprises the direction in which the fabric produced or conveyed. The term “cross-direction” or “CD”, as used herein, comprises the direction of the fabric substantially perpendicular to the MD.

The term “high-loft”, as used herein, comprises a material that comprises a z-direction thickness generally in excess of about 0.3 mm and a relatively low bulk density. The thickness of a “high-loft” nonwoven and/or layer may be greater than 0.3 mm (e.g., greater than 0.4 mm. greater than 0.5 mm, or greater than 1 mm) as determined utilizing a ProGage Thickness tester (model 89-2009) available from Thwig-Albert Instrument Co. (West Berlin, New Jersey 08091), which utilizes a 2″ diameter foot, having a force application of 1.45 kPa during measurement. In accordance with certain embodiments of the invention, the thickness of a “high-loft” nonwoven and/or layer may be at most about any of the following: 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75, and 0.5 mm and/or at least about any of the following: 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, and 2.0 mm. “High-loft” nonwovens and/or layers, as used herein, may additionally have a relatively low density (e.g., bulk density—weight per unit volume), such as less than about 70 kg/m³, such as at most about any of the following: 70, 60, 55, 50, 45, 40, 35, 30, and 25 kg/m3 and/or at least about any of the following: 10, 15, 20, 25, 30, 35, 40, 45, 50, and 55 kg/m³.

The term “crimp” or “crimped”, as used herein, comprises a three-dimensional curl or bend such as, for example, a folded or compressed portion having an “L” configuration, a wave portion having a “zig-zag” configuration, or a curl portion such as a helical configuration. In accordance with certain embodiments of the invention, the term “crimp” or “crimped” does not include random two-dimensional waves or undulations in a fiber, such as those associated with normal lay-down of fibers in a melt-spinning process.

As used herein, the term “aspect ratio”, comprise a ratio of the length of the major axis to the length of the minor axis of the cross-section of the fiber in question.

Whenever a melt flow rate (MFR) is referenced herein, the value of the MFR is determined in accordance with standard procedure ASTM D1238 (2.16 kg at 230° C.).

Certain embodiments according to the invention provide a spinneret for melt-spinning polymeric fibers including a spinneret body including a plurality of spinning orifices formed through a thickness of spinneret body, in which the plurality of spinning orifices include (i) a plurality of multicomponent spinning orifices comprising a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinning orifices comprising a single monocomponent opening; wherein the plurality of monocomponent spinning orifices may optionally include a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices. For example, the plurality of PCA monocomponent spinning orifices may be aligned with a different polymer source than the plurality of PCB monocomponent spinning orifices. Additionally or alternatively, the plurality of PCA monocomponent spinning orifices may have a different geometrical open area and/or size than the plurality of PCB monocomponent spinning orifices. In accordance with certain embodiments of the invention, the spinneret body may have a length and a width that is greater than the length. In this regard, the plurality of spinning orifices may define a plurality of rows extending independently from each other along at least about 20% of the width, such as at least about any of the following: 20, 30, 40, 50, 60, and 70% of the width, and/or, at most about any of the following: 100, 95, 90, 80, and 70% of the width.

In accordance with certain embodiments of the invention, the plurality of multicomponent spinning orifices may define at least one first zone, and the plurality of monocomponent spinning orifices may define at least one second zone. For example, the at least one first zone may comprise a first group of one or more rows including a first outermost row extending along a width direction of the spinneret body. Additionally or alternatively, the at least one first zone may comprise a second group of one or more rows including a second outermost row extending along the width direction of the spinneret body. Additionally or alternatively, the at least one second zone may comprise a third group of one or more rows extending along a width direction of the spinneret body and being located directly or indirectly between the first group of one or more rows and the second group of one or more rows.

FIG. 1A, for example, illustrates a spinneret 1 including a first zone comprising a first group of one or more rows or multicomponent spinning orifices 10 including a first outermost row extending along a width direction of the spinneret body and a second zone include a second group of one or more rows of monocomponent spinning orifices 20 including a second outermost row extending along a width direction of the spinneret body. FIG. 1B illustrates a spinneret 1 similar to that of FIG. 1A, but the plurality of monocomponent spinning orifices 20 includes a plurality of Polymeric Composition-A (PCA) monocomponent spinning orifices (i.e., identified with a “A” on FIG. 1B) and plurality of Polymeric Composition-B (PCB) monocomponent spinning orifices (i.e., identified with a “B” on FIG. 1B) in accordance with certain embodiments of the invention. As noted above, the plurality of PCA monocomponent spinning orifices may be aligned with a different polymer source than the plurality of PCB monocomponent spinning orifices. Additionally or alternatively, the plurality of PCA monocomponent spinning orifices may have a different geometrical open area and/or size than the plurality of PCB monocomponent spinning orifices. In the particular embodiment illustrated in FIG. 1B, the plurality of PCA monocomponent spinning orifices define a first outermost row of the plurality of spinning orifices, while the plurality of PCB monocomponent spinning orifices are located between and adjacent the plurality of PCA monocomponent spinning orifices and the one or more rows of multicomponent spinning orifices 10. FIG. 1C illustrates another spinneret 1 including a zone of multicomponent spinning orifices 10 and a zone of monocomponent spinning orifices 20 that includes an alternating pattern of a plurality of PCA monocomponent spinning orifices and a plurality of PCB monocomponent spinning orifices in accordance with certain embodiments of the invention

FIG. 2A, in accordance with certain embodiments of the invention, illustrates a spinneret 1 including a first zone comprising a first group of one or more rows of multicomponent spinning orifices 10 and a second group of one or more rows of multicomponent spinning orifices 15. The spinneret of FIG. 2 includes a relatively smaller second zone including a third group of one or more rows of monocomponent spinning orifices 20 that is located adjacent and between the first group of one or more rows of multicomponent spinning orifices 10 and the second group of one or more rows of multicomponent spinning orifices 15. In this regard, a resulting nonwoven fabric would have two outermost surfaces defined by multicomponent fibers (e.g., crimped) and an interior portion formed of monocomponent fiber that may provide enhanced strength and/or reduced elongation to the nonwoven fabric without negatively impacting the loft of the nonwoven fabric. FIG. 2B illustrates a spinneret 1 similar to that of FIG. 2A, but the zone of monocomponent spinning orifices 20 includes a plurality of PCA monocomponent spinning orifices and plurality of PCB monocomponent spinning orifices located adjacent and in between two zones of multicomponent spinning orifices in accordance with certain embodiments of the invention. The particular embodiment shown in FIG. 2B includes an alternating pattern of PCA monocomponent spinning orifices and PCB monocomponent spinning orifices along a row of spinning orifices.

In accordance with certain embodiments of the invention, the spinneret body may have a total number of rows, and the first group of one or more rows comprises about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18, and 20% of the total number of rows, and/or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22, and 20% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent). Additionally or alternatively, the spinneret body may have a total number of rows, and the second group of one or more rows comprises about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18, and 20% of the total number of rows, and/or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22, and 20% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent). Additionally or alternatively, the spinneret body may have s a total number of rows, and the third group of one or more rows may comprise about 10 to about 99% of the total number of rows, such as at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of rows, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent).

In accordance with certain embodiments of the invention and as illustrated by FIG. 3A, the spinneret 1 may include at least one second zone (i.e., monocomponent spinning orifices) may comprise a first group of one or more rows of monocomponent spinning orifices 20 including a first outermost row extending along a width direction of the spinneret body. Additionally, the at least one second zone may further comprise a second group of one or more rows of monocomponent spinning orifices 25 including a second outermost row extending along the width direction of the spinneret body. In accordance with certain embodiments of the invention, the at least one first zone (i.e., multicomponent spinning orifices) of the spinneret 1 may comprise a third group of one or more rows of multicomponent spinning orifices 10 extending along a width direction of the spinneret body and being located directly or indirectly between the first group of one or more rows of monocomponent spinning orifices 20 and the second group of one or more rows of monocomponent spinning orifices 25. FIG. 3B illustrates a spinneret 1 similar to that of FIG. 3A, but in which one of the smaller zones of monocomponent spinning orifices comprises a plurality of PCA monocomponent spinning orifices and the other smaller zone of monocomponent spinning orifices comprises a plurality of PCB monocomponent spinning orifices in accordance with certain embodiments of the invention.

In accordance with certain embodiments of the invention, the spinneret body may have a total number of rows, and the first group of one or more rows comprises about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18, and 20% of the total number of rows, and/or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22, and 20% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent). Additionally or alternatively, the spinneret body may have a total number of rows, and the second group of one or more rows comprises about 1 to about 45% of the total number of rows, such as at least about 1, 3, 5, 8, 10, 12, 15, 18, and 20% of the total number of rows, and/or at most about any of the following: 45, 40, 38, 35, 32, 30, 28, 25, 22, and 20% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent). Additionally or alternatively, the spinneret body may have a total number of rows, and the third group of one or more rows comprises about 10 to about 99% of the total number of rows, such as at least about 10, 12, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of rows, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number or rows. In accordance with certain embodiments of the invention, a given row may be classified in a particular zone if at least a majority of the spinning orifices are of a particular type (e.g., monocomponent or multicomponent).

In accordance with certain embodiments of the invention and as generally illustrated in FIGS. 3A-3B, the at least one first zone may comprise a plurality of first zones, and the at least one second zone comprises a plurality of second zones. For example, the plurality of first zones and the plurality of second zones may be located in an alternating pattern along a length direction of the spinneret as illustrated in FIG. 4 . In accordance with certain embodiments of the invention, the plurality of first zones and the plurality of second zones may be located in an alternating pattern along a width direction. In accordance with certain embodiments of the invention and as illustrated in FIG. 5 , the plurality of first zones (i.e., 10 a-10 j) and the plurality of second zones (i.e., 20 a-20 j) may be located in an alternating pattern along a length direction and a width direction. In accordance with certain embodiments of the invention, the example spinnerets of FIGS. 4 and 5 may include a plurality of PCA monocomponent spinning orifices and a plurality of PCB monocomponent spinning orifices as noted above.

FIG. 6 illustrates another spinneret 1, in accordance with certain embodiments of the invention, including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine-direction (MD) when in operation and a length direction (L) of the spinneret that may be associated with a cross-direction (CD) when in operation in accordance with certain embodiments of the invention. FIG. 7 illustrates another spinneret 1, in accordance with certain embodiments of the invention, including alternating zones of multicomponent spinning orifices and monocomponent spinning orifices along a length direction (L) of the spinneret that may be associated with a machine-direction (MD) when in operation and a length direction (L) of the spinneret that may be associated with a cross-direction (CD) when in operation in accordance with certain embodiments of the invention. In accordance with certain embodiments of the invention, the example spinnerets of FIGS. 6 and 7 may include a plurality of PCA monocomponent spinning orifices and a plurality of PCB monocomponent spinning orifices as noted above.

In accordance with certain embodiments of the invention, the at least one first zone (i.e., multicomponent spinning orifices) may comprise a continuous sea of the plurality of multicomponent spinning orifices, and the at least one second zone (i.e., monocomponent spinning orifices) may comprise a plurality of second zones comprising islands of monocomponent spinning orifices dispersed throughout the continuous sea of the plurality of multicomponent spinning orifices. FIG. 8 , for instance, illustrates a spinneret 1 including the at least one first zone (i.e., multicomponent spinning orifices) comprising a continuous sea of the plurality of multicomponent spinning orifices 10, and the at least one second zone (i.e., monocomponent spinning orifices) comprising a plurality of second zones comprising islands of monocomponent spinning orifices 20, 25, 28 dispersed throughout the continuous sea of the plurality of multicomponent spinning orifices 10. Alternatively, the at least one second zone may comprise a continuous sea of the plurality of monocomponent spinning orifices, and the at least one first zone comprises a plurality of first zones comprising islands of multicomponent spinning orifices dispersed throughout the continuous sea of the plurality of monocomponent spinning orifices. In accordance with certain embodiments of the invention, the example spinneret of FIG. 8 may include a plurality of PCA monocomponent spinning orifices and a plurality of PCB monocomponent spinning orifices as noted above. For example, island of monocomponent spinning orifices 25 may comprise PCA monocomponent spinning orifices and islands of monocomponent spinning orifices 20, 28 may comprise PCB monocomponent spinning orifices. Alternatively, each of the islands of monocomponent spinning orifices 20, 25, 28 may comprise a combination of a plurality of PCA monocomponent spinning orifices and a plurality of PCB monocomponent spinning orifices.

In accordance with certain embodiments of the invention, the plurality of multicomponent spinning orifices may comprise a round outermost cross-section, a non-round outermost cross-section, or both. Additionally or alternatively, the plurality of multicomponent spinning orifices may comprise an average open area at a discharging face of the spinneret body from about 60% to about 95%, such as at least about any of the following: 60, 65, 70, and 75%, and/or at most about any of the following: 95, 90, 85, 80, and 75%.

In accordance with certain embodiments of the invention, the plurality of multicomponent spinning orifices may comprise a round outermost cross-section having an aspect ratio from 0.8 to 1.2, such as about 0.8, 0.9, and 1, and/or at most about 1.2, 1.1, and 1. Additionally or alternatively, the plurality of multicomponent spinning orifices comprise a non-round outermost cross-section having an aspect ratio of at least 1.5, such as at least about any of the following: 1.5, 2, 3, 4, and 5, and/or at most about any of the following: 10, 9, 8, 7, 6, and 5.

The multicomponent spinning orifices, in accordance with certain embodiments of the invention, the first multicomponent opening and the separate second multicomponent opening may define a side-by-side configuration, a multi-lobal configuration, a sheath-and-core configuration, an islands-in-the-sea configuration wherein the separate second multicomponent opening comprises a plurality of such openings operatively connected to each other, or any combination thereof. In accordance with certain embodiments of the invention, the sheath-and-core configuration may include a core opening and a sheath opening, wherein the core opening defines at least a portion of an outermost circumference of the multicomponent spinning orifice having a round outermost cross-section or at least a portion of an outermost perimeter of the multicomponent spinning orifice having a non-round outermost cross-section.

The multicomponent spinning orifices, in accordance with certain embodiments of the invention, may comprise a combination of round outermost cross-section multicomponent spinning orifices and non-round outermost cross-section multicomponent spinning orifices. The round outermost cross-section multicomponent spinning orifices, in accordance of the invention may comprise from 1 to about 99% of a total number of the multicomponent spinning orifices, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the multicomponent spinning orifices, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the multicomponent spinning orifices. Additionally or alternatively, the non-round outermost cross-section multicomponent spinning orifices may comprise from 1 to about 99% of a total number of the multicomponent spinning orifices, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the multicomponent spinning orifices, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the multicomponent spinning orifices. In accordance with certain embodiments of the invention, the multicomponent spinning orifices may all be round or non-round.

In accordance with certain embodiments of the invention, the plurality of monocomponent spinning orifices comprise a round outermost cross-section having an aspect ratio from 0.8 to 1.2, such as about 0.8, 0.9, and 1, and/or at most about 1.2, 1.1, and 1. Additionally or alternatively, the plurality of monocomponent spinning orifices comprise a non-round outermost cross-section having an aspect ratio of at least 1.5, such as at least about any of the following: 1.5, 2, 3, 4, and 5, and/or at most about any of the following: 10, 9, 8, 7, 6, and 5.

In accordance with certain embodiments of the invention, the monocomponent spinning orifices may comprise a combination of round outermost cross-section monocomponent spinning orifices and non-round outermost cross-section monocomponent spinning orifices. In accordance with certain embodiments of the invention, the round outermost cross-section monocomponent spinning orifices may comprise from 1 to about 99% of a total number of the monocomponent spinning orifices, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the monocomponent spinning orifices, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the monocomponent spinning orifices. Additionally or alternatively, the non-round outermost cross-section monocomponent spinning orifices comprise from 1 to about 99% of a total number of the monocomponent spinning orifices, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the monocomponent spinning orifices, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the monocomponent spinning orifices. Alternatively, the monocomponent spinning orifices may all be round or non-round.

In accordance with certain embodiments of the invention, the plurality of spinning orifices of the spinneret may have or define a total number of spinning orifices. In accordance with certain embodiments of the invention, from about 1 to about 40% of the total number of spinning orifices may be monocomponent spinning orifices, such as at least about any of the following: 1, 2, 3, 5, 10, 12, 15, 18, and 20% of the total number of spinning orifices may be monocomponent spinning orifices, and/or at most about any of the following: 40, 38, 35, 33, 30, 28, 25, 22, and 20% of the total number of spinning orifices may be monocomponent spinning orifices. Additionally or alternatively, from about 60 to about 99% of the total number of spinning orifices may be multicomponent spinning orifices, such as at least about any of the following: 60, 62, 65, 67, 70, 72, 75, 78, and 80% of the total number of spinning orifices may be multicomponent spinning orifices, and/or at most about any of the following: 99, 98, 97, 95, 90, 88, 85, 82, and 80% of the total number of spinning orifices may be multicomponent spinning orifices.

In another aspect, the present invention also provides a die including (i) a spinneret as described and disclosed herein, (ii) a first polymer distribution pathway operatively connecting a first inlet to each of the first multicomponent openings of the plurality of multicomponent spinning orifices of the spinneret, (iii) a second polymer distribution pathway operatively connecting a second inlet to each of the second multicomponent openings of the plurality of multicomponent spinning orifices of the spinneret, and (iv) a third polymer distribution pathway operatively connecting a third inlet to at least a first portion of the monocomponent openings of the plurality of monocomponent spinning orifices of the spinneret, such as the plurality of PCA monocomponent spinning orifices; and (v) optionally a fourth polymer distribution pathway operatively connecting a fourth inlet to at least a second portion of the single monocomponent openings of the plurality of monocomponent spinning orifices of the spinneret, such as the plurality of PCB monocomponent spinning orifices. In accordance with certain embodiments of the invention, the die is a spunbond die configured for the formation of continuous fibers.

In another aspect, the present invention also provides a system including (i) a die as described and disclosed herein; (ii) a first polymer source comprising a first polymeric composition, wherein the first polymer source is operatively connected to a first inlet of the die, (iii) a second polymer source comprising a second polymeric composition that is different than the first polymeric composition, wherein the second polymer source is operatively connected to a second inlet of the die, and optionally (iv) a third polymer source comprising a third polymeric composition that is different than the first polymeric composition and the second polymeric composition, wherein the third polymer source is operatively connected to a third inlet of the die. In accordance with certain embodiments of the invention, the first polymer source or the second polymer source may also be operatively connected to the third inlet of the die.

In accordance with certain embodiments of the invention, they system further comprises a third polymer source comprising a third polymeric composition, in which the third polymer source is operatively connected to the third inlet. The third polymeric composition, for instance, may be different than the first polymeric composition and the second polymeric composition. Alternatively, the third polymeric composition may be the same as the first polymeric composition or the second polymeric composition. Additionally or alternatively, the system may comprise a fourth polymer source comprising a fourth polymeric composition, wherein the fourth polymer source is operatively connected to the fourth inlet; wherein the fourth polymeric composition is different from the third polymeric composition, and the fourth polymeric composition is the same or different than the first polymeric composition and/or the second polymeric composition.

In accordance with certain embodiments of the invention, the first polymer source comprises a first hopper, a first extruder, and a first metering pump, in which the first hopper has a first hopper outlet operatively connected to a first extruder inlet, and the first extruder has a first extruder outlet operatively connected to a first metering pump inlet, and the first metering pump has a first metering pump outlet operatively connected to the first inlet of the die. Additionally or alternatively, the second polymer source comprises a second hopper, a second extruder, and a second metering pump, in which the second hopper has a second hopper outlet operatively connected to a second extruder inlet, ant the second extruder has a second extruder outlet operatively connected to a second metering pump inlet, and the second metering pump has a second metering pump outlet operatively connected to the second inlet of the die. Additionally or alternatively, the third polymer source comprises a third hopper, a third extruder, and a third metering pump, in which the third hopper has a third hopper outlet operatively connected to a third extruder inlet, and the third extruder has a third extruder outlet operatively connected to a third metering pump inlet, and the third metering pump has a third metering pump outlet operatively connected to the third inlet of the die. Additionally or alternatively, the system may comprise a fourth polymer source comprising a fourth hopper, a fourth extruder, and a fourth metering pump, wherein the fourth hopper has a fourth hopper outlet operatively connected to a fourth extruder inlet, ant the fourth extruder has a fourth extruder outlet operatively connected to a fourth metering pump inlet, and the fourth metering pump has a fourth metering pump outlet operatively connected to the fourth inlet of the die.

In another aspect, the present invention also provides a nonwoven fabric including a plurality of interlaid fibers comprising a plurality of monocomponent fibers, such as optionally a plurality of different types of monocomponent fibers including a plurality of first type of monocomponent fibers and a plurality of second type of monocomonent fibers, and a plurality of crimped multicomponent fibers, in which the nonwoven fabric includes at least one first region including at least a majority (e.g., all) of a first monocomponent-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority (e.g., all) of a first multicomponent-fiber group of the plurality of crimped multicomponent fibers. In accordance with certain embodiments of the invention, different types of monocomponent fibers may be distinguished from each other as having a different polymeric composition, different cross-sections, different average diameters, or any combination thereof. For example, a plurality of first type of monocomponent fibers may comprises or consist of a particular polymeric composition (e.g., polymeric composition ‘A’) while the second type of monocomponent fibers may comprises or consist of a different polymeric composition (e.g., polymeric composition ‘B’).

Regardless of the particular number and/or relative locations of respective groups or zones of the different types of fibers (e.g., monocomponent and multicomponent fibers), in accordance with certain embodiments of the invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven may be from about 1 to about 40%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14 15, 18, and 20% by weight, and/or at most about any of the following: 40, 38, 35, 33, 30, 28, 26, 25, 24, 22, and 20% by weight. Additionally or alternatively, the total weight percentage of all multicomponent fibers based on the total amount of fibers forming the nonwoven may be from about 60 to about 99% by weight, such as at least about any of the following: 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80% by weight, and/or at most about any of the following: 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82, and 80% by weight.

In accordance with certain embodiments of the invention, the first monocomponent-fiber group defines a first outermost surface of the nonwoven fabric. Additionally or alternatively, the at least one first region further comprises a second monocomponent-fiber group of the plurality of monocomponent fibers, and wherein the second monocomponent-fiber group defines a second outermost surface of the nonwoven fabric. In accordance with certain embodiments of the invention, the first multicomponent-fiber group may be located adjacent to the first monocomponent-fiber group, the second monocomponent-fiber group, or both. Additionally or alternatively, the nonwoven fabric may have a total basis weight from about 10 grams-per-meter-squared (gsm) to about 200 gsm, such as at least about any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and/or at most about any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the first monocomponent-fiber group comprises from about 1 to about 30% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15% by weight of the total basis weight, and/or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15% by weight of the total basis weight. Additionally or alternatively, the second monocomponent-fiber group comprises from about 1 to about 30% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15% by weight of the total basis weight, and/or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15% by weight of the total basis weight. Additionally or alternatively, the first multicomponent-fiber group comprises from about 40 to about 98% by weight of the total basis weight, such as at least about any of the following: 40, 44, 48, 50, 52, 56, 60, 64, 68, and 70% by weight of the total basis weight, and/or at most about any of the following: 98, 96, 94, 90, 88, 84, 80, 76, 72, and 70% by weight of the total basis weight. In accordance with certain embodiments of the invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven may be from about 1 to about 40%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14 15, 18, and 20% by weight, and/or at most about any of the following: 40, 38, 35, 33, 30, 28, 26, 25, 24, 22, and 20% by weight. Additionally or alternatively, the total weight percentage of all multicomponent fibers based on the total amount of fibers forming the nonwoven may be from about 60 to about 99% by weight, such as at least about any of the following: 60, 62, 65, 67, 70, 72, 74, 75, 76, 78, 80% by weight, and/or at most about any of the following: 99, 98, 97, 95, 94, 92, 90, 88, 86, 85, 82, and 80% by weight.

In accordance with certain embodiments of the invention, the first multicomponent-fiber group defines a first outermost surface of the nonwoven fabric. Additionally or alternatively, the at least one second region further comprises a second multicomponent-fiber group of the plurality of multicomponent fibers, and wherein the second multicomponent-fiber group defines a second outermost surface of the nonwoven fabric. Additionally or alternatively, the first monocomponent-fiber group may be located adjacent to the first multicomponent-fiber group, the second multicomponent-fiber group, or both. Additionally or alternatively, the nonwoven fabric has a total basis weight from about 10 grams-per-meter-squared (gsm) to about 200 gsm, such as at least about any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and/or at most about any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the first multicomponent-fiber group comprises from about 1 to about 45% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, and 25% by weight of the total basis weight, and/or at most about any of the following: 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15% by weight of the total basis weight. Additionally or alternatively, the second multicomponent-fiber group comprises from about 1 to about 45% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, and 25% by weight of the total basis weight, and/or at most about any of the following: 45, 42, 40, 38, 35, 32, 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15% by weight of the total basis weight. Additionally or alternatively, the first monocomponent-fiber group comprises from about 10 to about 98% by weight of the total basis weight, such as at least about any of the following: 10, 16, 20, 24, 30, 36, 40, 44, 48, 50, 52, 56, 60, 64, 68, and 70% by weight of the total basis weight, and/or at most about any of the following: 98, 96, 94, 90, 88, 84, 80, 76, 72, 70, 64, 60, 56, and 50% by weight of the total basis weight. In accordance with certain embodiments of the invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven may be from about 1 to about 30%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15% by weight, and/or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

In accordance with certain embodiments of the invention, the at least one first region comprises a plurality of first regions, and the at least one second region comprises a plurality of second regions. For example, the plurality of first regions and the plurality of second regions may be located in an alternating pattern along a machine-direction of the nonwoven fabric, a z-direction that is perpendicular to the machine-direction and a cross-direction, or both. Additionally or alternatively, the plurality of first regions and the plurality of second regions may be located in an alternating pattern along a cross-direction of the nonwoven fabric, a z-direction that is perpendicular to the cross-direction and a machine-direction, or both. In accordance with certain embodiments of the invention, the plurality of first regions and the plurality of second regions may be located in an alternating pattern along a cross-direction and a machine-direction. In accordance with certain embodiments of the invention, the plurality of first regions and the plurality of second regions may also be located in an alternating pattern in a z-direction of the nonwoven fabric, wherein the z-direction is perpendicular to the cross-direction and the machine-direction. Additionally or alternatively, the nonwoven fabric may have a total basis weight from about 10 grams-per-meter-squared (gsm) to about 200 gsm, such as at least about any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and/or at most about any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the plurality of multicomponent fibers comprises from about 1 to about 95% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50% by weight of the total basis weight, and/or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50% by weight of the total basis weight. Additionally or alternatively, the plurality of monocomponent fibers comprises from about 1 to about 95% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50% by weight of the total basis weight, and/or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50% by weight of the total basis weight. In accordance with certain embodiments of the invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven may be from about 1 to about 30%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15% by weight, and/or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

In accordance with certain embodiments of the invention, the at least one second region may comprise a continuous network of the plurality of crimped multicomponent fibers, and the at least one first region comprises a plurality of first regions comprising separate islands of the plurality of monocomponent fibers dispersed throughout the continuous network of the plurality of crimped multicomponent fibers. Alternatively, the at least one first region comprises a continuous network of the plurality of monocomponent fibers, and the at least one second region comprises a plurality of second regions comprising separate islands of crimped multicomponent fibers dispersed throughout the continuous network of the plurality of monocomponent fibers. In accordance with certain embodiments of the invention, the nonwoven fabric may have a total basis weight from about 10 grams-per-meter-squared (gsm) to about 200 gsm, such as at least about any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 gsm, and/or at most about any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 gsm. Additionally or alternatively, the plurality of multicomponent fibers comprises from about 1 to about 95% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 40, 45, and 50% by weight of the total basis weight, and/or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50% by weight of the total basis weight. Additionally or alternatively, the plurality of monocomponent fibers comprises from about 1 to about 95% by weight of the total basis weight, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, 15, 18, 20, 22, 25, 30, 35, 45, and 50% by weight of the total basis weight, and/or at most about any of the following: 95, 90, 85, 80, 75, 70, 65, 60, and 50% by weight of the total basis weight. In accordance with certain embodiments of the invention, the total weight percentage of all monocomponent fibers based on the total amount of fibers forming the nonwoven may be from about 1 to about 30%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 14, and 15% by weight, and/or at most about any of the following: 30, 28, 26, 25, 24, 22, 20, 18, 16, and 15%.

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may comprise a round outermost cross-section, a non-round outermost cross-section, or both. The plurality of crimped multicomponent fibers may comprise a variety of cross-sectional geometries and/or deniers, such as round or non-round cross-sectional geometries. In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may comprise all or substantially all of the same cross-sectional geometry or a mixture of differing cross-sectional geometries to tune or control various physical properties.

Additionally or alternatively, the plurality of crimped multicomponent fibers may comprise an average cross-section (e.g., the longest cross-sectional length being perpendicular to length of the fiber) from about 8 to about 40 microns, such as at least about any of the following: 8, 10, 12, 15, 18, and 10 microns, and/or at most about any of the following: 70, 38, 35, 32, 30, 28, 25, 22, and 20 microns. In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may comprise round crimped multicomponent fibers having any of the average cross-section values or ranges noted above. Additionally or alternatively, the plurality of crimped multicomponent fibers may comprise non-round crimped multicomponent fibers having an average cross-section (e.g., the longest cross-sectional length being perpendicular to length of the fiber) from about 15 to about 40 microns, such as at least about any of the following: 15, 18, 20, 22, and 25 microns, and/or at most about any of the following: 40, 38, 35, 32, 30, 28, and 25 microns. By way of example only, the non-round fibers may comprise tri-lobal crimped multicomponent fibers having an average cross-section (e.g., the longest cross-sectional length being perpendicular to length of the fiber) from about 20 to about 30 microns, such as at least about any of the following: 20, 22, and 25 microns, and/or at most about any of the following: 30, 28, and 25 microns. By way of yet another example, the non-round fibers may comprise ribbon-shaped (e.g., rectangular-shaped) crimped multicomponent fibers having an average cross-section (e.g., the longest cross-sectional length being perpendicular to length of the fiber) from about 20 to about 30 microns, such as at least about any of the following: 20, 22, 24, and 25 microns, and/or at most about any of the following: 30, 28, 26, and 25 microns

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may comprise a round outermost cross-section having an aspect ratio from 0.8 to 1.2, such as about 0.8, 0.9, and 1, and/or at most about 1.2, 1.1, and 1. Additionally or alternatively, the plurality of crimped multicomponent fibers may comprise a non-round outermost cross-section having an aspect ratio of at least 1.5, such as at least about any of the following: 1.5, 2, 3, 4, and 5, and/or at most about any of the following: 10, 9, 8, 7, 6, and 5.

The crimped multicomponent fibers, in accordance with certain embodiments of the invention, may comprise a side-by-side configuration, a multi-lobal configuration, a sheath-and-core configuration, an islands-in-the-sea configuration, or any combination thereof. The sheath-and-core configuration, in accordance with certain embodiments of the invention, may comprise an eccentric sheath-and-core configuration wherein at least a portion of an outermost circumference of the crimped multicomponent fibers having a round outermost cross-section or at least a portion of an outermost perimeter of the crimped multicomponent fibers having a non-round outermost cross-section is defined by a core component. In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers comprise bi-component fibers.

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers comprise a combination of round outermost cross-section multicomponent fibers and non-round outermost cross-section multicomponent fibers. For example, the round outermost cross-section multicomponent fibers may comprise from 1 to about 99% of a total number of the multicomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the multicomponent fibers, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the multicomponent fibers. Additionally or alternatively, the non-round outermost cross-section multicomponent fibers comprise from 1 to about 99% of a total number of the multicomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the multicomponent fibers, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the multicomponent fibers. In accordance with certain embodiments of the invention, the crimped multicomponent fibers may all be round outermost cross-section multicomponent fibers or all be non-round outermost cross-section multicomponent fibers.

FIGS. 9A-9H illustrate examples of cross-sectional views for some non-limiting examples of the plurality of crimped multicomponent fibers in accordance with certain embodiments of the invention. As illustrated in FIG. 9A-9H, the crimped fiber 50 may comprise a first polymeric component 52 of a first polymeric composition A and a second polymeric component 54 of a second polymeric composition B. The first and second components 52 and 54 can be arranged in substantially distinct zones within the cross-section of the crimped fiber that extend substantially continuously along the length of the crimped fiber. The first and second components 52 and 54 can be arranged in a side-by-side arrangement in a round cross-sectional fiber as depicted in FIG. 9A or in a ribbon-shaped (e.g., non-round) cross-sectional fiber as depicted in FIGS. 9G and 9H. Additionally or alternatively, the first and second components 52 and 54 can be arranged in a sheath/core arrangement, such as an eccentric sheath/core arrangement as depicted in FIGS. 9B and 9C. In the eccentric sheath/core crimped fibers as illustrated in FIG. 9B, one component fully occludes or surrounds the other but is asymmetrically located in the crimped fiber to allow fiber crimp (e.g., first component 52 surrounds component 54). Eccentric sheath/core configurations as illustrated by FIG. 9C include the first component 52 (e.g., the sheath component) substantially surrounding the second component 54 (e.g., the core component) but not completely as a portion of the second component may be exposed and form part of the outermost surface of the fiber 50. As additional examples, the plurality of crimped multicomponent fibers can comprise hollow fibers as shown in FIGS. 9D and 9E or as multilobal fibers as shown in FIG. 9F. It should be noted, however, that numerous other cross-sectional configurations and/or fiber shapes may be suitable in accordance with certain embodiments of the invention. In the multi-component fibers, in accordance with certain embodiments of the invention, the respective polymer components can be present in ratios (by volume or by mass) of from about 85:15 to about 15:85. Ratios of approximately 50:50 (by volume or mass) may be desirable in accordance with certain embodiments of the invention; however, the particular ratios employed can vary as desired, such as at most about any of the following: 85:15, 80:20, 75:25, 70:30, 65:35, 60:40, 55:45 and 50:50 by volume or mass and/or at least about any of the following: 50:50, 45:55, 40:60, 35:65, 30:70, 25:75, 20:80, and 15:85 by volume or mass.

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may comprise self-crimping fibers, in which the crimped portions are formed during the laydown process. In this regard, the plurality of crimped multicomponent fibers may comprise (i) a first component comprising a first polymeric material having a first melt flow rate (MFR), such as optionally less than 500 g/10 min, less than 400 g/10 min, less than 300 g/10 min, less than 200 g/10 min, less than 100 g/10 min, or less than 50 g/10 min, and (ii) a second component comprising a second polymeric material that is different than the first component, in which the plurality of crimped multicomponent fibers comprises one or more three-dimensional crimped portions. Optionally the second polymeric material may comprises a second MFR that is, for example, optionally less than 2000 g/10 min, 1500 g/10 min, 1000 g/min, 10 min, 500 g/10 min, less than 400 g/10 min, less than 300 g/10 min, less than 200 g/10 min, less than 100 g/10 min, or less than 50 g/10 min. Additionally or alternatively, the plurality of crimped multicomponent fibers may comprise non-self-crimping fibers that require a post crimp-forming operation (e.g., heat activation) to impart that desired crimped portions.

As noted above, the plurality of crimped multicomponent fibers may comprise a first component comprising a first polymeric composition and a second component comprising a second polymeric composition, in which the first polymeric composition is different than the second polymeric composition. For example, the first polymeric composition may comprise a first polyolefin composition and the second polymeric composition may comprise a second polyolefin composition, a polyester, or a polyamide. In accordance with certain embodiments of the invention, the first polyolefin composition may comprise a first polypropylene or blend of polypropylenes and the second polyolefin composition may comprise a second polypropylene and/or a second polyethylene, in which the first polyolefin composition has, for example, a first melt flow rate and the second polymeric composition (e.g., a second polyolefin composition) has a second melt flow rate, in which the first melt flow rate is different than the second melt flow rate. Additionally or alternatively, the first polypropylene or blend of polypropylenes may have a lower degree of crystallinity than the second polymeric composition (e.g., a second polyolefin composition). In accordance with certain embodiments of the invention, the second polymeric composition, may comprise a polyester, a polyamide, or a bio-polymer (e.g., polylactic acid).

In accordance with certain embodiments of the invention, the first polymeric composition and the second polymeric composition can be selected so that the plurality of crimped multicomponent fibers develop one or more crimps therein without additional application of heat either in the diffuser section just after the draw unit but before laydown, once the draw force is relaxed, and/or post-treatments such as after fiber lay down and web formation. The polymeric compositions, therefore, may comprise polymers that are different from one another in that they have disparate stress or elastic recovery properties, crystallization rates, and/or melt viscosities. In accordance with certain embodiments of the invention, the polymeric compositions may be selected to self-crimp (e.g., a post-crimping operation may not be necessary after the laydown of the fibers from a spinneret) by virtue of the melt flow rates of the first and second polymeric compositions as described and disclosed herein. In accordance with certain embodiments of the invention, multi-component fibers, for example, can form or have crimped fiber portions having a helically-shaped crimp in a single continuous direction. For example, one polymeric composition may be substantially and continuously located on the inside of the helix formed by the crimped nature of the fiber. As noted above, the plurality of crimped multicomponent fibers may comprise non-self-crimping fibers that require a post crimp-forming operation (e.g., heat activation) to impart that desired crimped portions.

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may include (i) a first plurality of crimped multicomponent fibers having a first identifying feature, such as a first cross-sectional geometry, a first chemical construction, or a first crimp percentage per given length of fiber, and (ii) a second plurality of crimped multicomponent fibers having a second identifying feature, such as a second cross-sectional geometry, a second chemical construction, or a second crimp percentage per given length of fiber, in which the first identifying feature is different than the second identifying feature. The first plurality of crimped multicomponent fibers, for example, may include a polyolefin as at least a portion thereof (e.g., a component of a multicomponent fiber), and the second plurality of crimped multicomponent fibers may include a different polyolefin composition or a non-polyolefin as at least a portion thereof.

In accordance with certain embodiments of the invention, the plurality of crimped multicomponent fibers may include, for example, a first component (e.g., distinct phase) comprising or consisting of a polymeric material including a polyolefin, such as a polypropylene homopolymer, and a second component (e.g., distinct phase) comprising or consisting of a different polymeric material including a different polyolefin, such as a polypropylene copolymer. The polypropylene copolymer, for example, may be a polypropylene random copolymer or a polypropylene block copolymer. The polypropylene copolymer, for example, may include a minor weight % of a C₂, or C₄-C₈ α-olefin units distributed throughout the polypropylene copolymer. For example, the C₂, or C₄-C₈ α-olefin units may account for about 1 to about 20% by weight of the propylene copolymer, such as at least about any of the following: 1, 2, 3, 5, 6, 8, and 10% by weight of the propylene copolymer, and/or at most about any of the following: 20, 18, 16, 15, 14, 12, and 10% by weight of the propylene copolymer. In accordance with certain embodiments of the invention, the first component (e.g., polypropylene homopolymer) may account from about 20 to 80% by weight of the crimped multicomponent fibers, such as at least about any of the following: 20, 25, 30, 35, 40, 45, 50, 55, and 60% by weight of the crimped multicomponent fibers, and/or at most about any of the following: 80, 75, 70, 65, and 60% by weight of the crimped multicomponent fibers. Additionally or alternatively, the second component (e.g., polypropylene copolymer) may account from about 20 to 80% by weight of the crimped multicomponent fibers, such as at least about any of the following: 20, 25, 30, 35, 40, 45, 50, 55, and 60% by weight of the crimped multicomponent fibers, and/or at most about any of the following: 80, 75, 70, 65, and 60% by weight of the crimped multicomponent fibers.

In accordance with certain embodiments of the invention, the plurality of monocomponent fibers, may comprise, for example, a plurality of first type of monocomponent fibers comprising a third polymeric composition that is different than the first polymeric composition and the second polymeric composition. Alternatively, the plurality of monocomponent fibers may comprise, for example, a plurality of first type of monocomponent fibers comprising a third polymeric composition that is the same as the first polymeric composition or the second polymeric composition. For example, the third polymeric composition may comprise a third polyolefin composition, a polyester, or a polyamide. In accordance with certain embodiments of the invention, the third polyolefin composition may comprise a third polypropylene or blend of polypropylenes and/or a third polyethylene. Additionally or alternatively, the third polymeric composition may comprise a bio-polymer (e.g., polylactic acid). In accordance with certain embodiments of the invention, the plurality of monocomponent fibers, may comprise, for example, a plurality of second type of monocomponent fibers comprising a fourth polymeric composition that is different than the third polymeric composition, and wherein the fourth polymeric composition may be different than the first polymeric composition and the second polymeric composition. Alternatively or additionally, the plurality of monocomponent fibers may comprise, for example, a plurality of second type of monocomponent fibers comprising a fourth polymeric composition that is different than the third polymeric composition, and wherein the fourth polymeric composition may be the same as the first polymeric composition or the second polymeric composition. For example, the fourth polymeric composition may comprise a fourth polyolefin composition, a polyester, or a polyamide. In accordance with certain embodiments of the invention, the fourth polyolefin composition may comprise a fourth polypropylene or blend of polypropylenes and/or a fourth polyethylene. Additionally or alternatively, the fourth polymeric composition may comprise a bio-polymer (e.g., polylactic acid).

In accordance with certain embodiments of the invention, the plurality of monocomponent fibers may include, for example, a polymeric material comprising a polymer component that comprises or consists of a polyolefin (e.g., a polypropylene homopolymer or a polypropylene copolymer). In accordance with certain embodiments of the invention, the plurality of monocomponent fibers may include, for example, a polymeric material that is entirely different from each of those used in the multicomponent fibers or the same as one of the polymeric materials used in the multicomponent fibers. For example, the plurality of multicomponent fibers may comprise at least one component comprising or consisting of polypropylene copolymer as noted above. In accordance with certain embodiments of the invention, the plurality of monocomponent fibers may comprises a polymer material having a polymer component that comprises or consists of a polypropylene copolymer (e.g., same or different from that of the multicomponent fibers). The polypropylene copolymer of the plurality of monocomponent fibers, for example, may be a polypropylene random copolymer or a polypropylene block copolymer. The polypropylene copolymer, for example, may include a minor weight % of a C2, or C4-C8 α-olefin units distributed throughout the polypropylene copolymer. For example, the C2, or C4-C8 α-olefin units may account for about 1 to about 20% by weight of the propylene copolymer, such as at least about any of the following: 1, 2, 3, 5, 6, 8, and 10% by weight of the propylene copolymer, and/or at most about any of the following: 20, 18, 16, 15, 14, 12, and 10% by weight of the propylene copolymer.

In accordance with certain embodiments of the invention, the plurality of monocomponent fibers may comprise all round outermost cross-section monocomponent fibers or all non-round outermost cross-section monocomponent fibers. Alternatively, the plurality of monocomponent fibers may comprise a combination of round outermost cross-section monocomponent fibers and non-round outermost cross-section monocomponent fibers. For example, the round outermost cross-section monocomponent fibers may comprise from 1 to about 99% of a total number of the monocomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the monocomponent fibers, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the monocomponent fibers. Additionally or alternatively, the non-round outermost cross-section monocomponent fibers comprise from 1 to about 99% of a total number of the monocomponent fibers, such as at least about any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the monocomponent fibers, and/or at most about any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the monocomponent fibers.

In accordance with certain embodiments of the invention, the nonwoven fabric may have a density of less than about 70 kg/m³, such as at most about any of the following: 70, 60, 55, 50, 45, 40, 35, 30, and 25 kg/m³ and/or at least about any of the following: 10, 15, 20, 25, 30, 35, 40, 45, 50, and 55 kg/m³. Additionally or alternatively, the nonwoven fabric may have a thickness in a z-direction that is perpendicular to a machine-direction and a cross-direction of the nonwoven fabric, the thickness comprising from about 0.3 mm to about 4 mm, such as at most about any of the following: 4, 3.8, 3.5, 3.2, 3, 2.75, 2.5, 2.25, 2, 1.75, 1.5, 1.25, 1.0, 0.75, and 0.5 mm and/or at least about any of the following: 0.3, 0.4, 0.5, 0.75, 1.0, 1.25, 1.5, 1.75, and 2.0 mm.

In accordance with certain embodiments of the invention, the nonwoven fabric may have a bonded area from about 1% to about 40%, such as at least about any of the following: 1, 2, 3, 5, 6, 8, 10, 12, 15, 18, 20, 21, and 22%, and/or at most about any of the following: 40, 38, 35, 32, 30, 28, 25, and 22%. In this regard, the bonded area may be defined by a plurality of separate bonded sites, such as a plurality of thermal point bonds (e.g., via thermal calendaring or ultrasonic bonding). Alternatively, the nonwoven fabric is through-air-bonded.

In accordance with certain embodiments of the invention, the nonwoven fabric may have a Delta PillGrade value (i.e., PillGrade value prior to abrasion via a Martindale Abrasion Tester minus the PillGrade value after abrasion by a predefined number of rubs via the Martindale Abrasion Tester) after 60 rubs from about 0.05 to about 0.35, such as at least about any of the following: 0.05, 0.08, 0.1, 0.15, and 0.2, and/or at most about any of the following: 0.35, 0.32, 0.3, 0.25, and 0.2. Additionally or alternatively, the nonwoven fabric may have a Delta PillGrade value after 120 rubs from about 0.05 to about 0.6, such as at least about any of the following: 0.05, 0.08, 0.1, 0.15, 0.2, 0.25, and 0.3, and/or at most about any of the following: 0.6, 0.55, 0.5, 0.45, 0.4, 0.35, 0.32, and 0.3. Additionally or alternatively, the nonwoven fabric may have a Delta PillGrade value after 180 rubs from about 0.1 to about 0.8, such as at least about any of the following: 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, and 0.4, and/or at most about any of the following: 0.8, 0.75, 0.7, 0.65, 0.6, 0.55, 0.5, 0.45, and 0.4.

In yet another aspect, the present invention also provides a method of producing a nonwoven fabric, such as those described and disclosed herein. The method, in accordance with certain embodiments of the invention, may include the following: (i) simultaneously melt spinning a set of fibers from a single spinneret, such as those described and disclosed herein, in which the set of fibers comprise a plurality of monocomponent fibers, such as optionally a plurality of different types of monocomponent fibers including a plurality of first type of monocomponent fibers and a plurality of second type of monocomonent fibers, and a plurality of multicomponent, and wherein the set of fibers form at least one first region including at least a majority of a first monocomponent-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority of a first multicomponent-fiber group of the plurality of multicomponent fibers; (ii) collecting the melt-spun set of fibers; and (iii) forming a plurality of crimped multicomponent fibers by actively and/or passively forming one or more crimped portions in at least a portion of the plurality of multicomponent fibers.

In accordance with certain embodiments of the invention, the step of forming the plurality of crimped multicomponent fibers may comprise allowing the multicomponent fibers to self-crimp during a laydown process prior to the step of collecting the melt-spun fibers. Additionally or alternatively, the step of forming the plurality of crimped multicomponent fibers may comprise actively subjecting the multicomponent fibers to a sufficient amount of heat to induce formation of the one or more crimped portions, in which the step of actively subjecting the multicomponent fibers to heat is performed prior to and/or after the step of collecting the melt-spun set of fibers. In accordance with certain embodiments of the invention, the method may comprise the combination of passively allowing the multicomponent fibers to self-crimp during a laydown process prior to the step of collecting the melt-spun fibers and further subjecting these fibers to an active crimp-forming process.

In accordance with certain embodiments of the invention, the method may comprise a step of consolidating the melt-spun fibers (e.g., consolidating the melt-spun nonwoven web to form the nonwoven fabric). The consolidation method may comprise a thermal bonding operation, such as a thermal calendaring operation, a thermal area bonding operation, or an ultrasonic bonding operation. Alternatively, the consolidation method may comprise a through-air-bonded process.

Examples

The present disclosure is further illustrated by the following examples, which in no way should be construed as being limiting. That is, the specific features described in the following examples are merely illustrative and not limiting.

A variety of lofty spunbond nonwoven fabrics were made that highlight some of the benefits (e.g., increased abrasion resistance as illustrated by a PillGrade measurement as discussed below) associated with lofty spunbond nonwoven fabrics formed from a spinneret including a combination of bicomponent spinning orifices forming crimped bicomponent spunbond fibers having a side-by-side configuration and monocomponent spinning orifices. Samples 1 and 2 are control samples in which all of the fibers are crimped spunbond fibers, but use a different combination of polymeric materials (e.g., polymers) for forming the respective components of the fibers. Samples 3-6 illustrate lofty spunbond nonwoven fabrics in accordance with certain embodiments of the invention, in which the spinneret used to form the samples provided 70% by number of crimped bicomponent fibers and 30% by number of monocomponent fibers.

Each of the samples were produced from one or more of the following polymers:

Polymer 1 was a polypropylene homopolymer (i.e., Exxon PP3155 from Exxon) having a MFR of 36 g/10 min per ASTM D1238 (230° C./2.16 kg), and a melting temperature of 165° C.

Polymer 2 was a propylene random copolymer having a MFR of 32 g/10 min per ASTM D1238 (230° C./2.16 kg), a melting temperature of 149° C.

Polymer 3 was a different propylene random copolymer having a MFR of 35 g/10 min per ASTM D1238 (230° C./2.16 kg), a melting temperature of 143° C.

Sample 1:

Sample 1 was a first control in which the nonwoven fabric consisted of 100% of crimped bicomponent fibers in which a first component was formed from Polymer 1 and a second component was formed from Polymer 2. Polymer 1 accounted for 60% by weight and Polymer 2 accounted for 40% by weight.

Sample 2:

Sample 2 was a second control in which the nonwoven fabric consisted of 100% of crimped bicomponent fibers in which a first component was formed from Polymer 1 and a second component was formed from Polymer 3. Polymer 1 accounted for 60% by weight and Polymer 3 accounted for 40% by weight.

Sample 3:

Sample 3 represents one example nonwoven fabric in accordance with certain embodiments of the invention. This nonwoven fabric was formed from 70% by number of crimped bicomponent fibers and 30% monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 2, in which Polymer 1 accounted for 60% by weight of the bicomponent fibers and Polymer 2 accounted for 40% by weight of the bicomponent fibers. The monocomponent fibers were made from polymer 1.

Sample 4:

Sample 4 represents another example nonwoven fabric in accordance with certain embodiments of the invention. This nonwoven fabric was formed from 70% by number of crimped bicomponent fibers and 30% monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 3, in which Polymer 1 accounted for 60% by weight of the bicomponent fibers and Polymer 3 accounted for 40% by weight of the bicomponent fibers. The monocomponent fibers were made from polymer 1.

Sample 5:

Sample 5 represents another example nonwoven fabric in accordance with certain embodiments of the invention. This nonwoven fabric was formed from 70% by number of crimped bicomponent fibers and 30% monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 2, in which Polymer 1 accounted for 60% by weight of the bicomponent fibers and Polymer 2 accounted for 40% by weight of the bicomponent fibers. The monocomponent fibers were made from polymer 2.

Sample 6

Sample 6 represents another example nonwoven fabric in accordance with certain embodiments of the invention. This nonwoven fabric was formed from 70% by number of crimped bicomponent fibers and 30% monocomponent fibers provided from the same spinneret. The bicomponent fibers were formed from Polymer 1 and Polymer 3, in which Polymer 1 accounted for 60% by weight of the bicomponent fibers and Polymer 3 accounted for 40% by weight of the bicomponent fibers. The monocomponent fibers were made from polymer 3.

Testing Protocol Representative of Abrasion Resistance

A 1300 Martindale Abrasion and Pilling Tester having 9 testing positions and a PillGrade testing unit, commercially available from SDL ATLAS, were each used to evaluate the abrasion resistance of each sample. In particular, portions of each sample was subjected to the Martindale Abrasion Testing per ASTM D4970 or ISO 12945-2 on the embossed roll side, in which spec Setup B (9 kPa weight, 60 rubs, 120 rubs, and 180 rubs were performed, 47.5 rpm speed). In this regard, the side of the nonwoven that was adjacent the embossing roll was rubbed against the opposite side of the nonwoven (e.g., any rubber is therefore removed from the top part and the nonwoven is placed on the supporting foam directly). In this regard, respective portions of each sample were subjected to Martindale Abrasion Testing of 60 rubs, another portion of each sample of 120 rubs, and another portion of each sample of 180 rubs.

After each of the respective sample portions were subjected to the respective number of rubs per the Martindale Abrasion Test, a virgin sample portion (e.g., pre-rubbed sample portion) of each sample as well as each respective sample portion subjected to Martindale Abrasion Testing was tested by the PillGrade unit per ASTM D4970 or ISO 12945-2, which measures abrasion impacts on fabric with a value of ‘5’ being not abraded with lower values or scores representative of the fabric showing more “pills” or entangled fibers or eventually “small balls” of fiber (e.g., increased abrasion). Stated somewhat differently sample portions of the samples before abrasion testing, and after the noted cycles (60, 120, and 180 rubs via Martindale Abrasion Testing), are then taken to a PillGrade testing unit for measurement of “Pillgrade” (e.g., values of ‘5’ being low to zero abrasion while values closer to ‘0’ represent larger quantities or levels of abrasion).

In this regard, a comparison of the numeric grade of “pilling” between various samples were obtained to illustrate the improved abrasion resistance of nonwoven fabrics in accordance with certain embodiments of the invention. Ultimately a score or value closer to “5” or the delta between the pre-abrasion value (i.e., not rubbed in the Martindale Abrasion Test unit), and post-rubbing at different cycles determines the abrasion performance. In this regard, the smallest delta or difference between the pre-abrasion values (i.e., ‘0’ rubs) and the numeric rubs is the best performing material. Table 1 provides a summary of the respective Pillgrade values.

TABLE 1 Pill Grade Pill Grade Pill Grade Pill Grade Pill Grade Pill Grade Pill Grade Pill Grade Pill Grade before after Difference before after Difference before after Difference Avg Martindale Martindale between ′0′ Martindale Martindale between ′0′ Martindale Martindale between difference (i.e., with rubs and (i.e., with rubs and (i.e., with ′0′ rubs and 60, 120, BW- Caliper 0 rubs) 60 rubs ′60′ rubs 0 rubs) 120 rubs ′120′ rubs 0 rubs) 180 rubs ′180′ rubs 180 Sample gsm [μm] 0 Rubs 60 Rubs avg loss 0 Rubs 120 Rubs avg loss 0 Rubs 180 Rubs avg loss avg loss Sample 1 23.3 275 4.89 4.33 0.56 5 4.12 0.88 4.92 4.13 0.79 0.74 Sample 2 23.3 270 4.84 4.6 0.24 4.87 3.8 1.07 4.94 4.17 0.77 0.69 Sample 3 21.7 268 5 4.67 0.33 4.89 4.37 0.52 5 4.43 0.57 0.47 Sample 4 21.7 269 5 4.92 0.08 5 4.77 0.23 5 3.88 1.12 0.48 Sample 5 22 249 5 4.85 0.14 5 4.94 0.05 5 4.74 0.26 0.15 Sample 6 22 265 5 4.79 0.21 4.94 4.71 0.23 4.94 4.65 0.29 0.24

As illustrated by the data from Table 1, Samples 3-6 all showed notably improved abrasion resistance compared to the controls (i.e., Samples 1 and 2) as evident by the reduced average difference value reported in the rightmost column of Table 1 (e.g., the average difference value for the average loss after 60 rubs, the average loss after 120 rubs, and the average loss after 180 rubs). Samples 5 and 6 each illustrate the unexpected results of forming the monocomponent fiber from a propylene random copolymer. The average difference value reported in the rightmost column of Table 1 for Sample 5 was ‘0.15’ while Sample 6 was ‘0.24’, which were from 30-50% of the values of Samples 3-4 and from 20-35% of the values of Sample 1-2.

These and other modifications and variations to the invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and it is not intended to limit the invention as further described in such appended claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein 

1. A spinneret for melt-spinning polymeric fibers, comprising: a spinneret body including a plurality of spinning orifices formed through a thickness of spinneret body; wherein the plurality of spinning orifices include (i) a plurality of multicomponent spinning orifices comprising a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinning orifices comprising a single monocomponent opening.
 2. The spinneret of claim 1, wherein the spinneret body has a length and a width that is greater than the length, and wherein the plurality of spinning orifices define a plurality of rows extending independently from each other along at least about 20% of the width.
 3. The spinneret of claim 1, wherein the plurality of multicomponent spinning orifices define at least one first zone, and the plurality of monocomponent spinning orifices define at least one second zone.
 4. The spinneret of claim 3, wherein the at least one first zone comprises a plurality of first zones, and the at least one second zone comprises a plurality of second zones.
 5. The spinneret of claim 1, wherein the multicomponent spinning orifices including the first multicomponent opening and the separate second multicomponent opening define a side-by-side configuration, a multi-lobal configuration, a sheath-and-core configuration, an islands-in-the-sea configuration wherein the separate second multicomponent opening comprises a plurality of such openings operatively connected to each other, or any combination thereof.
 6. The spinneret of claim 1, wherein the plurality of spinning orifices define a total number of spinning orifices, and wherein the plurality of multicomponent spinning orifices comprise from about 60 to about 99% of the total number of spinning orifices, the plurality of monocomponent spinning orifices comprise from about 1 to about 40% of the total number of spinning orifices.
 7. A nonwoven fabric, comprising: a plurality of interlaid fibers comprising a plurality of monocomponent fibers and a plurality of crimped multicomponent fibers, wherein the nonwoven fabric includes at least one first region including at least a majority of a first monocomponnet-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority of a first multicomponent-fiber group of the plurality of crimped multicomponent fibers.
 8. The nonwoven fabric of claim 7, wherein the first monocomponnet-fiber group defines a first outermost surface of the nonwoven fabric.
 9. The nonwoven fabric of claim 8, wherein the at least one first region further comprises a second monocomponnet-fiber group of the plurality of monocomponent fibers, and wherein the second monocomponnet-fiber group defines a second outermost surface of the nonwoven fabric, and wherein the first multicomponent-fiber group is located adjacent to the first monocomponnet-fiber group, the second monocomponnet-fiber group, or both.
 10. The nonwoven fabric of claim 7, wherein the first multicomponent-fiber group defines a first outermost surface of the nonwoven fabric.
 11. The nonwoven fabric of claim 10, wherein the at least one second region further comprises a second multicomponent-fiber group of the plurality of multicomponent fibers, and wherein the second multicomponent-fiber group defines a second outermost surface of the nonwoven fabric, and wherein the first monocomponent-fiber group is located adjacent to the first multicomponent-fiber group, the second multicomponent-fiber group, or both.
 12. The nonwoven fabric of claim 7, wherein the at least one first region comprises a plurality of first regions, and the at least one second region comprises a plurality of second regions.
 13. The nonwoven fabric of claim 12, wherein the plurality of first regions and the plurality of second regions are located in an alternating pattern along a machine-direction of the nonwoven fabric, a z-direction that is perpendicular to the machine-direction and a cross-direction, or both.
 14. The nonwoven fabric of claim 12, wherein the plurality of first regions and the plurality of second regions are located in an alternating pattern along a cross-direction of the nonwoven fabric, a z-direction that is perpendicular to the cross-direction and a machine-direction, or both.
 15. The nonwoven fabric of claim 12, wherein the plurality of first regions and the plurality of second regions are located in an alternating pattern along a cross-direction and a machine-direction.
 16. The nonwoven fabric of claim 12, wherein the plurality of first regions and the plurality of second regions are also located in an alternating pattern in a z-direction of the nonwoven fabric, wherein the z-direction is perpendicular to the cross-direction and the machine-direction.
 17. The nonwoven fabric of claim 7, wherein the at least one second region comprises a continuous network of the plurality of crimped multicomponent fibers, and the at least one first region comprises a plurality of first regions comprising separate islands of the plurality of monocomponent fibers dispersed throughout the continuous network of the plurality of crimped multicomponent fibers.
 18. The nonwoven fabric of claim 7, wherein the at least one first region comprises a continuous network of the plurality of monocomponent fibers, and the at least one second region comprises a plurality of second regions comprising separate islands of crimped multicomponent fibers dispersed throughout the continuous network of the plurality of monocomponent fibers.
 19. The nonwoven fabric of claim 7, wherein the nonwoven fabric has a total basis weight and the plurality of monocomponent fibers account for about 1 to about 40% by weight of the total basis weight, and/or the plurality of multicomponent fibers account for about 60 to about 99% by weight of the total basis weight.
 20. A method of producing a nonwoven fabric, comprising: (i) simultaneously melt spinning a set of fibers from a single spinneret, the set of fibers comprising a plurality of monocomponent fibers, and a plurality of multicomponent, wherein the set of fibers form at least one first region including at least a majority of a first monocomponent-fiber group of the plurality of monocomponent fibers and at least one second region including at least a majority of a first multicomponent-fiber group of the plurality of multicomponent fibers; (ii) collecting the melt-spun set of fibers; and (iii) forming a plurality of crimped multicomponent fibers by actively and/or passively forming one or more crimped portions in at least a portion of the plurality of multicomponent fibers. 